AQUATO K-Pilot 8.3 User manual

Version 01.06.2011
Operating instructions
aquato
K-Pilot Control

These operating instructions are available for you to
download in DIN A4 format as a PDF file on our home
page www.aquato.de in the “Downloads” section.

Table of contents
1 General description 4
2 Safety instructions 4
2.1 Identification of instructions in the operating instructions 4
2.2 Please note 4
3 Connections 6
3.1 Mains connection 6
3.2 7-pole plug 6
3.2.1 Submerged aerator 6
3.2.2 Filling/sludge pump 6
3.2.3 Clear water pump 6
3.2.4 Float switch 6
3.3 Floating contact 6
4 Function 7
4.1 Operation and displays 7
4.2 Commissioning 8
4.3 Main display 8
5 Menu 9
5.1 Menu structure 9
5.2 Runtime display 10
5.3 Service menu 10
5.3.1 System test / test mode 10
5.3.2 Manual mode 11
5.3.3 Select plant size 11
5.3.4 Phosphate elimination 11
5.4 Basic settings 12
5.4.1 Date and time 12
5.4.2 Alarm buzzer 12
5.4.3 Display errors (log book) 12
5.4.4 Language 12
5.4.5 LCD contrast 13
5.4.6 Clear alarm 13
5.5 System menus for individual settings 13
5.5.1 Aeration 13
5.5.2 Denitrification 13
5.5.3 Parameters 14
5.5.4 Current monitor 14
6 Malfunctions / Alarm 14
7 Power failure alarm 15
8 Assembly instructions 15
9 Technical data 16
10 Default settings 16
11 Switching times 17
12 Error messages 17
13 Notes 18
14 Manufacturer certification 19

2.1. Identification of instructions in the operating instructions
The safety instructions included in this doc. which could endanger persons if they are not observed
are identified with the general hazard symbol.
Electrical voltage warnings are specially indicated with the following symbol.
2.2 Please note
Continued on page 5
These operating instructions apply exclusively to the switching device (control) and contain
important instructions and warnings.
The operating instructions must be read prior to the assembly and commissioning by the
fitter and the responsible operator of the plant and observed.
Not only the general safety instructions listed under the main entry “Safety instructions” need
to be observed, but rather all the special safety instructions included under the following main
points.
These operating instructions do not take all design individualities and versions into account,
nor all the possible eventualities and results which might arise during assembly, operation
and maintenance.
Prerequisite for the assembly and handling of the switching device is the deployment of specially trained
personnel (see EN 50 110-1). Should you require information and instructions that you cannot find in
these operating instructions, please do not hesitate to consult the manufacturer.
The manufacturer and supplier of the switching device accepts no responsibility in cases where the
instructions are not observed.
4
1 General description
2 Safety instructions
The switching device controls a submerged aerator, a filling- / sludge pump and a clear water
outflow pump of a small wastewater treatment plant in accordance with the SBR principle in cycles.
When in operation the currents of the motors are monitored in order to identify plant errors as
much as possible. With the K-Pilot 8.4 it is also possible to connect a unit for dosing a precipitant
for phosphate elimination.

These operating instructions include important information which must be observed when setting-up,
commissoning and operating the plant. These operating instructions must be kept readily available
at the place where the plant is employed.
The control may only be connected and maintained by a
suitably qualified specialist.
PPrior to commissioning and turning on the mains it must be ensured that
- the device and the power supply cords are free from visible damage
- in particular the mains connections and the motor connections are connected up properly
- all connections have been performed correctly and expertly
- the laying and conducting of all cables and cords complies with the applicable regulations
- the device is correctly closed
- the plant is expertly fused
The respectively applicable regulations (EN, VDE, ...) And the regulations of the local energy
supplier must be observed.
If a fuse is defective, it must only be replaced with a microfuse of the following type:
microfuse, time-lag, type 3,15 A , 5 x 20 mm in accordance with EN 60127-2/III with a maximum
power loss of 1,5 W. This fuse is also inserted in the factory.
Note:
A stronger fuse can be employed for larger plants (max. 6,3 AT).
Fuses must always be replaced with a fuse of equal strength.
Prior to replacing the fuse, ensure that the device is completely turned off and disconnected from
the electricity supply (unplug).
Ensure device is turned off and disconnected from the
power supply before opening it (Unplug!).
Caution:
- Sensitive components
- Risk internal cabling can become loose
- live parts
5
2 Safety instructions
Always unplug before working on pumps and aerator!

3.3 Floating contact
The floating contact can be used to connect an additional warning
lamp / flashing light.
This can be supplied with electricity via the control or over another
independent / external cable.
In the case of an alarm, the relay closes the connection between
clips 11 and 12 and opens the connection between 11 and 14.
Continued on page 7
3.1 Mains connection
The plant is connected to the mains by means of the supplied power cable (approx. 1,5 m long) with
Shock-proof plug (clips L1, N, PE). Fuse protection on line side: max. 1 x 16 AG.
3.2 7 - pole plug
The following inputs and outputs are routed through a 7 - pole plug on the underside of the device.
3.2.1 Submerged aerator
The submerged aerator is connected via the 7 - pole plug on the underside of the housing.
3.2.2 Filling / sludge pump
The pump is connected via the 7 - pole plug on the underside of the housing.
3.2.3 Clear water pump
The clear water pump is connected via the 7 - pole plug on the underside of the housing.
3.2.4 Float switch
The float switch is connected via the 7 - pole plug on the underside of the housing.
Control voltage: 230 V~ approx. 5 mA, switching between input and N.
Cutting through the control cable results in loss of warranty!
6
3 Connections
Connector assignment of 7 –pole plug (as delivered)
No.Cable colour Function
1Black Submerged aerator
2Brown Filling / sludge pump
3Purple Clear water outflow
4Blue N (neutral wire)
5Orange Switch contact float switch
6White N (float switch)
7Green / Yellow Earth wire

4 Function
7
If you want the warning light / flashing light to illuminate / flash in the event of an error, it should
be connected via contacts 11 and 12 (see diagram).
For continuous illumination, the connection between 11 and 14 should be chosen.
3 Connections
4.1 Operation and displays
The control has a graphic LCD - display mit 128 x 64 pixels.
The displays appear in plain text.
It is operated via three buttons and two LEDs.
The green LED is illuminated continuously if a motor is on.
In the event of an malfunction / error, the red LED flashes. I
If both the green and red LEDs are illuminated continuously, the unit is in the
initialisation phase.
During normal operation, the green LED flashes and in addition a flashing triangle can be seen in
the lower right handcorner of the LCD display.
Each menu is composed of a row of displays on the LDC display.
You can change from menu to menu using the arrow keys .
By pressing the key you can enter the input mode for the respective menu.
The input mode can be identified by a selected (shown reversed) line.
The keys can now be used to select the lines and the key used to change the value.
If a multi-digit numerical input is required, the highest digit is changed first.
You can use the key to proceed on to the next digit and so on.
If the input is a selection from several options (e.g., YES / NO), the required selection can be
reached using the arrow keys .
When the required option appears on the display, it can be confirmed using the key.

4.3 Main display
In the standard display, the control shows the switching status of the plant and the motors, e.g.:
1. line: Date and time
2. line: Current SBR cycle
2. line (right): Normal or eco-mode operation of plant, (remaining)
time that the current phase has left
3. line: Display of which motor is running or “motors off”, if all the
motors are turned off
4. line: Operating current of the motors
5. line: Error display
6. line: Floater status up or down
If the key is pressed, the following appears:
- Version
- Date of version
- Type (set PT)
- Effluent class
The key can also be used to turn off the buzzer in this menu (see also 5.4.6)
8
4.2 Commissioning
When commissioning the unit, the following information must be entered first:
- Password
- Language (see menu item 5.4.4)
- Date and time (see menu item 5.4.1)
- Plant size (see menu item 5.3.3)
- Denitrification (see menu item 5.5.2)
- PO -elimination (only for type K-Pilot 8.4, see menu item 5.3.4)
3
- Test mode - lasts approx. 1 minute (see menu item 5.3.1)
Following the test mode, a window appears with the prompt input ok?. This can be answered with
YES / NO. If the input is NO, you start again by entering the password, if YES, the standard
display is shown.
The commissioning engineer must ensure that the parameters are set in such a
way that they comply with any requirements from the construction approval for
the plant on which the control is intended to be employed.
4 Function

Denitrification menu is only
visible with denitrification is
activated!
5.1 Menu structure
9
5 Menu

5 Menu
The exact display is dependent on the plant´s status and the set parameters.
The different display versions are described in more detail below.
5.2 Runtime display
The menu item “runtime” displays the runtimes of the respective
motors. The runtimes are counted when the control has turned
on the aerator or the pumps.
The display shows hours and minutes.
The runtimes of the last (up to 52) weeks can be viewed by
pressing the key (operations diary).
The last line shows the date of the week (e.g., CW 52) in which
the values were saved (always Sunday).
The keys can be used to change from week to week.
Note:
This function only works correctly if the date and time have been
set correctly.
The runtimes of the dosing pump are only shown when
phosphate elimination is active.
5.3 Service menu
The service menu is basically intended for the service technician.
The following are typically selected:
- Change password (only with special password)
- System test / test mode
- Manual mode
- Clear counter (only with special password)
- Select plant size
5.3.1 System test / test mode
The automatic test mode is selected via the selection menu
“start test”.
The test mode checks whether the motors accept current properly.
In addition, the float switch is raised to test the function of the
float switch.
The main display changes during test mode.
10